Method and means for converting tubular knitted fabric to open width



y 1968 E. COHN ET AL METHOD AND MEANS FOR CONVERTING TUBULAR KNITTED FABRIC TO OPEN WIDTH Filed NOV. 19, 1965 FIG. I

GATHER SLIT AND OPEN DISTEND AND STEAM EDGE RELOCATlON SUPPLY OF FLAT TUBULAR FABRIC FIG. 3

vmons EUGENE COHN SARGENT P SNYDER FRANK CATALLO ATTOR EYS United States Patent 3,3313% METHOD AND MEANS FQR CONVERTING TUEBEL LAll KNETTED lFABRMI Tit OPEN WHDTH Eugene Colin, Great Neck, Sargent l. Snyder, Springfield Gardens, and Frank Catallo, Elmont, N.Y., as-

signors to Samcoe Holding Corporation, Woodside,

N.Y., a corporation of New York Filed Nov. 19, 1965, er. No. 508,699

' 16 Claims. (til. 332) ABSTRACT OF THE DISQLOSURE This disclosure is concerned with a method and ap' paratus for converting tubular knit fabrics to open width form. A novel method is disclosed for substantially removing discernible edge creases from the fabric by steaming the fabric tube while the discernible edge creases are maintained under lateral tension and free of frictional engagement by the apparatus. The disclosed method for removing discernible edge creases may also include the step of reorienting a flat fabric tube before steaming, to relocate the discernible edge creases in offset relation to the actual edges of the fiat fabric tube.

The present invention relates to the processing and treatment of tubular knitted fabric, and is directed more specifically to a novel and advantageous procedure and t apparatus for effecting the conversion of tubular knitted fabric to open Width form.

Because of the significant conveniences and economies realized in the manufacturing process, knitted fabrics currently are widely manufactured by means of circular knitting machines, Which are arranged to construct the fabric in the form of a continuous length of tubing. For many ultimate uses, the fabric may be utilized substantially in its tubular form, as in the making of T-shirts, polo shirts, etc. In many instances, however, and apparently to an increasing degree according to current market trends, it is desirable to utilize the tubular knitted fabric in flat, open Width form. This is accomplished by, at some stage, slitting the knitted fabric tube longitudinally and laying the fabric open in fiat, full width form.

Although the tubular knitted fabric, intended for utilization as open Width fabric, may be slit and opened immediately after construction or at any subsequent stage in its processing, it appears to be more expedient, in most instances, to complete a significant amount of the fabric processing while the fabric remains intact in its original tubular form, to take advantge of certain conveniences in the handling of the fabric in tubular form vis-a-vis open Width form. Such processing typically might include washing, bleaching, scouring, dyeing, resin impregnating, setting to predetermined Width dimensions, calendering and/ or compacting, and the like.

During the handling and processing of tubular knitted fabric, at least during the subsequent stages of processing, it is advantageous to handle the fabric as an intact tube, but in fiat, two-layer form. At various stages, the fiat fabric tube is rolled and/ or gathered in folds, and it may also be passed through one or more sets of nipping rollers and otherwise handled and treated. Such handling tends to cause edge creases to appear in the fabric, at the actual side edges of the flattened tube. Typically, when the fabric subsequently is slit along the centerline of the tube and laid open, the edge creases tend to remain in the fabric as longitudinal ridges spaced one-quarter Width in from the new side edges of the open width fabric. These ridges may be tolerated for some end uses of the fabric, but prove disadvantageous for others. Attempts have 3,381,397 Patented May 7 1968 been made, heretofore, to minimize the effect of the edge creases by slitting along one edge of the fabric tube, so that one of the edge creases is divided by the cut, and the resulting half ridges are located at the edge extremities of the open Width fabric; but this does not completely solve the problem for all end uses, because at least one edge crease remains, and edge slitting can in some instances introduce additional handling difficulties in connection with the laying open of the slit fabric to its open width form.

In accordance with the invention, a novel and advantageous procedure is provided for converting tubular knitted fabric to flat, open width knitted fabric substantially free of edge crease ridges. Broadly stated, the procedure of the invention comprises initially manipulating the knitted fabric tube so that its initially discernible edge creases are relocated and displaced from the actual side edges of the reformed or reoriented tube. Thereafter, the tube is subjected to a lateral distention and steamed, such that the longitudinal ridges, formed by the initially discernible edge creases, are substantially or completely removed from the fabric. The treated fabric, now without any significant edge creases whatever, is slit longitudinally, advantageously along the centerline of the reoriented fabric tube. The axis of the slit may coincide with the axis of the initially discernible edge crease, and this will be advantageous in particularly difficult cases Where the prior distending and steaming of the fabric did not remove the initially discernible edge crease to percent perfection. After slitting, the fabric is manipulated in the absence of nipping pressure to direct the slit edges divergently outward and convert the fabric to its desired, flat, open width form.

As a significant aspect of the invention, the knitted fabric is so handled and manipulated between the point of its being steamed under lateral distention to the point of its conversion to open Width form that, although the initially discernible edge creases are removed, significantly discernible creases are not newly formed in other 10- cations. This objective is realized by avoiding the application of nipping or other pressure to the fabric while it remains in two-layer form. Most advantageously, no nipping pressure Whatever is utilized, although it is conceivable that a very, very slight pressure could be tolerated, provided it Was insufficient to re-form edge creases.

Ideally, slitting and converting to open Width form are performed in as close'coupled sequence as is practicable, consistent with physical requirements of the equipment.

For a better understanding of the invention, reference should be made to the following detailed description and to the accompanying drawing, in which:

FIG. 1 is a simplified schematic representation of the method according to the invention for converting processed tubular knitted fabric to flat, open Width fabric substantially free of discernible ridges resulting from edge creases;

FIG. 2 is a simplified side elcvational view of an apparatus for performing the method of FIG. 1; and

FIG. 3 is a top plan view of the apparatus of FIG. 2.

With reference now to the drawing, the process in its most basic form is represented by the schematic diagram of FIG. 1, reading from left to right. Thus, the process commences at a supply stage 10, in which conventional tubular knitted fabric is supplied in flat tubular form. At this stage, the fabric often will have undergone previous treatment, such that the supply fabric is in flat, twolayered form, with substantial uniformity of width dimension. Typically, at this stage, the fabric will be in substantially finished form, although the process frequently will be carried outwith grey goods, which have not yet undergone the before-described treatments but nevertheless will have acquired undesirable edge creases.

Because of the various previous treatments, the fabric delivered at the supply stage will contain initially discernible creases at its side edges which, after slitting and opening of the fabric in accordance with conventional procedures, will remain as undesirable ridges. Accordingly, the second stage of the process involves manipulation of the tubular knitted fabric to a new fiat, two-layered form, in which the initially discernible edge creases are reoriented or relocated so as to lie well inside of the actual edges of the newly formed fabric tube, and most desirably along the centerline axis of the reoriented tube.

In the third stage 12 of the process, the reoriented fabric tube, still in fiat, two-layered form, is distended in :a lateral direction, sufficient to assure good control over the handling of the fabric and to tend to draw the initially discernible edge creases out into the principal planes of the fabric layers. While the fabric is thus slightly distended and controlled, it is steamed in at least those longitudinal areas encompassing the initially discernible edge creases, thereby enabling the fabric structure in the crease area to be re-formed sufficiently to substantially or entirely remove the initial edge creases.

After removal of the initially discernible edge creases, the fabric is directed through a slitting and opening stage 13, in which the tube is cut open longitudinally and then spread to flat, open width form. The open width fabric then is rolled or folded in a gathing stage 14.

In accordance with the invention, after elimination of the initially discernible edge creases in the distending and steaming stage 12, the fabric is guided and directed in a manner to remain free of roll nip pressure acting upon more than one layer of the fabric and is otherwise handled in such a way as to prevent the formation of new discernible edge creases in the fabric. Thus, the fabric reaching the gathering stage 14 is substantially free of any ridge or other deformity resulting from edge creasing of the fabric while being handled in tubular form, either before or after slitting.

Referring now more specifically to FIGS. 2 and 3 of the drawing, the reference numeral 15 designates a typical supply container for holding processed tubular knitted fabric. In the illustrated arrangement, the supply container 15 is illustrated as holding the fabric in folded form, although the supplied fabric may be in roll or otherwise suitably gathered form, as will be understood. In accordance with the invention, the supplied fabric 16 having edge creases 17 is drawn from the supply container 15, typically over a guide roller 18, and is directed over an edge relocating frame designated generally by the reference numeral 19. In passing over the edge relocating frame 19, the fabric tube is reoriented from one fiat, two-layered form to another. In the reoriented tube,

the initially discernible edge creases 17 are relocated to a point between the actual side edges 20 of the reoriented tube and, as illustrated in FIG. 3, the initially discernible edge creases 17 advantageously are relocated along the center-line of the reoriented tube.

Although it should be understood that the specific form of the fabric reorienting frame 19 does not form a critical part of the present invention, it is particularly advantageous to utilize in this system the reorienting frame shown and described in the copending application of Frank Catallo et al., Ser. No. 466,026, filed June 22, 1965, now Patent No. 3,337,107, and owned by the assignee of the instant application. Although reference may be had to that copending application for further details concerning the reorienting frame, it should be sufiicient for the purpose of understanding this invention to consider the frame 19 as comprising, as its basic elements, a first guide frame section 21 for supplied fabric, a reorienting frame section 22, and a guide frame section 23 for the reoriented fabric. The reorienting frame section 22 advantageously is -a square frame disposed at right angles 41 to the travel of the supplied fabric web 16. The respective guide frame sections 21, 23 are disposed on opposite sides of the reorienting frame, disposed along the opposite diagonals of the square frame. Pairs of small diameter guide rollers 24, 25 are provided in the corner areas defined by the principal planes of the frame sections 21-23, so that the fabric remains in fiat, two-layer form as it. traverses the reorienting frame structure, all as described in greater detail in the beforementioned copending application of Frank Catallo et a1.

As shown particularly in FIG. 3, the reoriented fabric 26 travels at right angles to the direction of the supplied fabric 16, primarily as a matter of convenience in order that the fabric tube may have a substantially horizontal disposition before and after reorientation in the frame 19.

After reorientation, the fabric is advanced over a spreader propeller assembly, advantageously of the general type described and claimed in the 'S. Cohn United States Patent No. 2,228,001. The spreader, which is designated generally by the numeral 27, advantageously is arranged to distend the fabric tube in a lateral direction, so as to maintain firm control over the fabric and, more importantly, to exert widthwise tension on the ridges formed in the fabric by the initially discernible edge creases 17. While the fabric is passing over the spreader 27, steam is applied to the fabric, as by conventional steam boxes 28, 29, typically across the entire width of the fabric but at least in the specific areas of the initially discernible edge creases 17. This permits a reformation of the fabric structure, particularly in the areas of the initially discernible edge creases, so that the previously creased or ridged areas of the fabric become flat and smooth.

After steaming of the fabric under widthwise tension, to substantially or completely remove the initially discernible edge creases, the fabric is advanced by the spreader 27 through a slitting stage, in which one layer of the fiat tube is slit longitudinally, as by a rotating slitting knife 30. To facilitate opening of the slit fabric in the absence of distortion, it is advantageous to slit the flat tube along its centerline, as reflected in FIG. 3. In addition, it is advantageous to align the slitting axis with one of the initially discernible edge creases so that, if there is any residual trace of an edge crease after steaming, it will be split apart with the individual halves of the residual trace being disposed at the opposite edges of the open width fabric. In the specifically illustrated apparatus, the foregoing considerations are accommodated in an optimum manner by aligning the fabric in the reorienting stage such that the initially discernible edge creases are disposed along the centerline of the reoriented tube.

Substantially immediately after slitting of the reoriented tube, the slit edges 31, 32 are guided and directed divergently outward and other longitudinal portions of the fabric are so guided and directed that the fabric is converted from slit tubular form to flat open width form, as shown at 33, in the absence of significant tensions and distortions placed upon the fabric. A specifically advantageous form of apparatus for effecting conversion of the fabric to open width form constitutes the subject matter of copending application Ser. No. 513,516, filed Dec. 13, 1965, although it will be understood that other equipment and procedures may be utilized in effecting conversion of the slit fabric from tubular to open width form.

In accordance with one of the significant aspects of the invention, the fabric is handled and manipulated subsequent to the steaming stage in such a way that it is maintained free of nipping pressure which would tend to form new creases in the fabric. In other words, the fabric is maintained free of pressure applied to any folded over edges while the fabric is being conveyed and converted to open width form.

In the specifically illustrated form of equipment for converting the fabric from tubular to open width form,

which corresponds generally to the equipment described and claimed in the above-mentioned copending application Ser. No. 513,516, the slit fabric is first directed through a pair of control rollers 34, 35. These rollers, while arranged as an opposed pair, are specifically maintained in separated relation so as not to apply nipping or creasing pressure to the fabric. At the same time, the rollers are provided with surface coverings of a character which can exert a tractive gripping force on the upper and lower layers of the fabric, so that the fabric is maintained under control and is urged to advance in a forward direction by the rollers 34, 35, which are suitably driven.

As the slit fabric, still in tubular form, emerges on the exit side of the roller pair 34, 35', the slit edges 31, 32 are directed generally horizontally outward and around a side portion 36 of a guide frame 37. Center portions of the fabric are directed upward and around central portions of the guide frame. The fabric travels around the guide frame 37 and under a guide roller 38, at which point the fabric has assumed a flat, open width form, at approximately twice the Width of the tubular fabric advanced over the spreader frame 27. The open width fabric can be suitably gathered as in the form of a roll 39 supported on wind-up rollers 40.

The finished, open width fabric in its gathered form is substantially free of any ridges which otherwise would remain in the open width fabric by reason of the presence of one or more of the initially discernible edge creases of a conventionally processed tubular knitted fabric. This renders the finished, open width material more suitable and desirable for subsequent handling and cutting into garments and other final configurations, as will be readily appreciated, and therefore represents significant added value.

The procedure of the invention, in its most basic form, involves initially reorienting a previously processed tubular knitted fabric to dispose its initially discernible edge creases somewhere between the actual edges of the reoriented fabric. Thereafter and while the reoriented fabric is maintained under at least slight lateral tension, at least the initially discernible edge crease areas of the fabric are steamed and the edge creases are thereby wholly or at least substantially removed. The fabric is then slit and converted to open width form, being handled at all times subsequent to the steaming operation in such a manner as to avoid the formation of new discernible creases.

Although the invention has been illustrated and described with reference to certain specific apparatus deemed advantageous for the purpose, it should be particularly undesrtood that any of a wide variety of equipments may be utilized in the practice of the invention. Accordingly, reference should be made to the following appended claims in deter-mining the full scope of the invention.

We claim:

1. The method of converting tubular knitted fabric to flat, open width knitted fabric, which comprises i (a) supplying tubular knitted fabric in a form having initially discernible edge creases,

(b) disposing and guiding the supplied fabric in flat, two-layer, tubular form, with said edge creases being located in displaced relation with respect to the side edges of the guided fabric tube,

(c) steaming the guided fabric tube to substantially remove the discernible edge creases,

(d) slitting one layer of the guided fabric tube,

(e) opening to flat form and gathering the slit fabric,

and

(f) maintaining the steamed fabric substantially free of nipping pressure at the edges prior to opening.

2. The method of claim 1, further characterized by (a) said fabric being supplied in generally flat, twolayer, tubular form, with said initially discernible edge creases at the edges thereof, and

(b) prior to said disposing and guiding step, the supplied fabric being reoriented to relocate said edge creases.

3. The method of claim 2, further characterized by (a) the guided fabric tube being slit substantially along the centerline of the guided tube.

4. The method of claim 2, further characterized by (a) said initially discernible edge creases being re-- located to positions substantially along the centerline of the guided fabric tube, and

(b) one layer of said fabric being slit substantially along one of said initially discernible edge creases.

5. The method of converting tubular knitted fabric to flat, open width knitted fabric, which comprises (a) supplying the tubular knitted fabric in a fiat, twolayer, tubular form having initially discernible edge creases at the edges of the tube,

(b) reorienting the supplied fabric tube to a new flat,

two-layer, tubular form to dispose its initially discernible edge creases between the edges of the newly formed flat tube,

(c) laterally distendi-ng the reoriented tube and steaming the distented fabric,

(d) slitting one layer of the steamed fabric,

(e) opening to fiat form and gathering the fabric, and

(f) maintaining the reoriented fabric substantially free of discernible creases along the edges of the reoriented tube.

6. The method of claim 5, further characterized by (a) said reoriented fabric tube being slit along a cutting line substantially coincident with one of said initially discernible edge creases.

7. The method of claim 6, further characterized by (a) said cutting line being substantially along the centerline of the reoriented tube.

8. The method of claim 5, further characterized by (a) said fabric being slit substantially along the centerline of the reoriented tube,

(b) the slit edges being directed divergently from said centerline to form side edges of the opened fabric,

(c) said divergently directed slit edges being retained substantially in a predetermined plane, and

(d) portions of said fabric between said slit edges being controllably diverted out of said plane and then directed back into it, whereby all portions of the fabric travel substantially equal distances between slit-ting and gathering.

9. The method of converting tubular knitted fabric to fiat, open width form, which comprises (a) supplying tubular knitted fabric in a fiat, two layer form having initially discernible edge creases located in offset relation to the actual edges of the supplied fabric,

(b) placing at least those longitudinal portions of the fabric tube which include the edge creases under internal lateral distention,

(c) steaming the distended fabric in the area of at least one of said initially discernible edge creases, (d) slitting the fabric in the area of the other of said initially discernible edge creases, and

(e) opening to flat form and gathering the slit fabric.

10. Apparatus for converting tubular knitted fabric to fiat, open width form, which comprises (a) means for supplying the tubular knitted fabric in fiat, two layer form with initially discernible edge creases,

(b) means for reorienting the fabric tube to locate the initially discernible edge creases between the actual edges of the fabric tube,

(0) means for internally engaging and laterally distending the reoriented fabric tube,

(d) steam applicator means disposed above or below the distending means and arranged to apply steam to said distended fabric at least in the longitudinal area including one of said initially discernible edge creases,

(e) means for slitting the fabric tube longitudinally substantially along the other of said initially discernible edge creases, and

(f) means for opening to flat, full-width form and gathering the slit fabric.

11. Apparatus according to claim 10, further characterized by (a) said opening and gathering means including means for guiding and directing the material free of nipping pressure from said slitting means until said fabric is in single layer form.

12. Apparatus for converting tubular knitted fabric to flat, open Width form, which comprises (a) means for supplying the tubular knitted fabric in flat, two-layer form with initially discernible edge creases at the actual side edges of the tube,

(b) means for reorienting the fabric tube to a new flat form, with said initially discernible edge creases located substantially centrally between the actual side edges of the reoriented flat tube,

(c) means located adjacent the discharge side of said reorienting means for spreading the fabric to fiat form at a uniform predetermined distended width and conveying the fabric forward,

(d) means positioned above and/or below the spreading means for steaming the spread fabric sufiiciently to substantially eliminate said initially discernible edge creases,

(e) means for slitting the steamed fabric, and

(f) means for opening to flat, full-width form and gathering the slit fabric.

13. Apparatus according to claim 12, further characterized by (a) said slitting means being aligned with and adapted to cut substantially along one of said initially discernible edge creases.

14. The method of converting tubular knitted fabric to fiat, open width form, which comprises (a) supplying tubular knitted fabric in a flat, two layer form having initially discernible edge creases located at the actual edges of the supplied fabric tube,

(b) placing at least those longitudinal portions of the fabric tube which include the edge creases under internal lateral distention,

(c) steaming the distended fabric to substantially reduce the discernibility of the edge creases,

(d) slitting the fabric tube longitudinally,

(e) opening to flat form and gathering the slit fabric,

(f) maintaining the steamed fabric substantially free of nipping pressure at the edges prior to opening, and

(g) reorienting the supplied fabric tube in advance of steaming and slitting to displace said initially discernible edge creases from the actual edges of the fabric tube.

15. The method of converting tubular knitted fabric to flat, open width form, which comprises (a) supplying tubular knitted fabric in a form having initially discernible edge creases,

(b) applying internal distention forces transverse to the discernible edge creases to at least those longitudinal portions of the fabric tube which include the edge creases,

(c) said edge creases being substantially free from frictional restraint during the application of said distention forces, thereby maximizing the effect of said distention forces on said edge crease,

(d) steaming at least those longitudinal portions of the fabric tube which include the distended edge creases to substantially reduce the discernibility of the edge creases,

(e) slitting the fabric longitudinally,

(f) opening to flat form and gathering the slit fabric,

and

(g) maintaining the steamed fabric, substantially free of nipping pressure prior to opening.

16. The method of claim 15, further characterized by (a) the distention forces being applied laterally, and

(b) said fabric tube being slit substantially along the axis of one of the initially discernible edge creases.

References Cited UNITED STATES PATENTS ANDREW R. JUHASZ, Primary Examiner. 

